Packaging apparatus and process



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PACKAGING APPARATUS AND PROCESS Filed Nov. 22,l 1963 18 Sheets-$heet 1'/ June 6, 1967 C. K, LEE ET AL PACKAGING APPARATUS AND PROCESS 18 Sheets-Sheet la Filed Nov. 22, 1963 United States Patent O 3,323,273 PACKAGING APPARATUS AND PROCESS Claude K. Lee, Bourbonnais, Ill., Harry E. Rothmann,

Valhalla, N.Y., William C. Storey, Kankakee, Ill., and

George M. Woodruff, Thornwood, N.Y., assignors to General Foods Corporation, White Plains, N.Y., a corporation of Delaware Filed Nov. 22, 1963, Ser. No. 325,686 36 Claims. (Cl. 53-24) This invention relates generally to an apparatus and method for forming and wrapping in individual packages a malleable, semi-solid product, capable of being molded into a desired packaged configuration. More particularly, the invention relates to an apparatus and method of the above character wherein a wrapper blank having easyopening features is fabricated from roll stock, applied to a volumetrically measured quantity of the product formed by the apparatus into a desired shape and then sealed to provide an air and moisture barrier for the product, all of these operations being performed in a continuous, high speed, fully automatic manner.

The invention is disclosed herein in an embodiment adapted for packaging within a contour wrapper a food product processed into a ground or shredded condition, the individual shreds or pellets of which are combined and molded into a disclike or waferlike form which will hereinatter be referred to as a patty, although it should be understood that the precise nature of the product or the precise form into which it is molded are not essential aspects yof the inventive concepts herein disclosed. Also, in the present embodiment of the invention use is made of a wrapper material which is transparent and moistureimpervious to a relatively high degree, since the ability to see the product within the wrapper and the `retention of moisture within the product are valuable attributes in the merchandising of products of this character. However, as will be apparent from the following description, the invention is in no way dependent upon wrapping material having these attributes. Y In carrying out the invention, use is made of an endless chain of unique and novel construction strung about and reaching between two separated and opposed turret members, each having rotating sprocket means cooperating with the chain. The chain is driven continuously, and each link thereof comprises a mold into which a measured quantity of the loose product is placed to be formed by cooperating members into the desired configuration such as that of a patty. The input of the loose bulk product, measuring thereof and forming thereof into the patty shape is accomplished while the individual links of the chain pass around one of said turret members, and sealing of the edges of the wrapper blank to complete the packaging operation is accomplished while individual links of the chain pass around the other turret member.

Disposed along the front straight reach of the chain is a wrapper blank fabricating mechanism which produces individual wrapper blanks, having novel easy-opening features, from continuous rolls of wrapper material and which applies a blank to each link of the chain in a position to cover the mold defined thereby. Thus, as each link subsequently arrives at the product-forming stage of the chain travel, the wrapper blank is applied to the product concomitantly with the molding of the product into the patty form, and by the same means. In this manner there is performed at one and the same time and in one operation procedures which in prior machines of this character have required two or more distinct and separate processing steps, thereby giving rise to a more simplified and higher speed packaging operation than has heretofore been possible.

Disposed along the rear straight reach of the chain extending between the two turret members is novel wrapping mechanism for folding down the edges of the wrapper blank in preparation for the sealing operation, the wrapping mechanism being specially designed for operating on a continuously moving package and for assuring that a predetermined edge of the wrapper blank is the last edge to be folded down for facilitating the easy opening of the sealed package as will hereinafter become apparent.

It is therefore an object of lthis invention to improve upon an apparatus and method for forming a product, supplied in bulk form, into a desired shape and applying a contour wrapper thereto.

It is a further object of this invention to provide an improved apparatus and process for fabricating wrapper blanks from rolls of wrapper material, forming a product into a desired shape for wrapping and applying a wrapper blank to said formed product as a contour wrapper in a continuous, high speed and fully automatic manner.

It is a further object of the invention to provide an irnproved apparatus and process for fabricating a wrapper blank having easy opening features.

It is a further object of the invention to provide an improved apparatus and process for folding down the edges of the wrapper blank so as to render it a contour wrapper for the contained product.

Further objects of the invention, together with the features contributing thereto and the advantages accruing therefrom will be apparent from the following description when read in conjunction with the drawing wherein:

FIG. 1 is a front elevation of the machine;

FIG. 2 is a layout depicting the contour of the camming means associated with the product forming members in yrelation to the plane of the associated product forming chain throughout the course of the chains path of travel;

FIG. 3 is a plan view of the machine;

FIG. 4 is a plan view in enlarged scale of one of the links of the product forming chain;

FIG. 5 is an end view in elevation of the chain link shown in FIG. 4;

FIG. 6 is a sectional view taken along the lines 6--6 of FIG. 4 and including portions of adjacent links of said chain;

FIG. 7 is a view in front elevation of the wrapper fab-` ricating mechanism;

FIG. 8 is a detailed view partly in section of a portion of the wrapper fabricating mechanism;

FIG. 9 is a detailed sectional view of the wrapper slitting means and pull tab applicator means taken along the line 9--9 of FIG. 8;

FIG. 10 is a sectional View through the Wrapper yedge sealing rolls taken along the line 10-104 of FIG. 7;

FIG. l1 is a sectional View of the wrapper fabricating mechanism taken along the line 11-11 of FIG. 8;

FIG. 12 is a sectional view showing the wrapper pleat former taken along the line 12-12 of FIG. 7;

FIG. 13 is a sectional View Iof the wrapper fabrication driving means taken along the line 13--13 of FIG. 3;

FIG. 14 is a plan view of a portion of the product forming chain and cooperating sprocket means associated with the product forming turret;

FIG. 15 is a perspective view of a portion `of the product forming turret at the product receivinglocation thereof;

FIG. 16 is a perspective view of said turret at the product forming location thereof;

FIG. 17 is a sectional view through a portion of the product forming turret taken along the line 17--17 of FIG. 3;

F'IG. 18 is a detailed view of the wrapper blank cutoff roll taken along the line 18-18 of FIG. 7;

FIG. 19 is a view in elevation of the wrapper edge folding mechanism;

FIG. 20 is a sectional view through the wrapper edge folding mechanism taken along the line 20--20` of FIG. 19;

FIG. 21 is a plan view of the wrapper edge folding mechanism shown in FIGS. 19 and 20;

FIG. 22 is a detailed sectional View in enlarged scale of fold retaining mechanism taken along -t-he line 22-22 of FIG. 21;

FIG. 23 is a plan view of the wrapper sealing turret withthe cover removed;

FIG. 24 is a sectional view through the Wrapper sealing turret taken along the line 24--24 of FIG. 23;

FIG. 25 is a perspective view of the package ejecting mechanism;

FIG. 26 is a plan View of the package ejecting mechamsm;

FIG. 27 is a perspective view of the wrapper blank showing the two laminations thereof in exploded relation to one another;

FIG. 28 is a view `of the patty formed product with the wrapper blank partly enveloping same;

FIG. 29 is a view similar to FIG. 28, but with the 'trailing edge end corners folded down against the product;

FIG. 30 is a view similar to FIG. 29 showing all but the leading edge of the wrapper blank folded against the product;

FIG. 3l is a View similar to FIG. 30 showing all edges and corners of the wrapper blank folded down against the product;

FIG. 32 is a perspective View of the wrapped product Y linverted from the position shown in FIG. 31;

FIG. 33 is a sectional view in enlarged scale to the wrapper blank taken along the line 33-33 of FIG. 27;

FIG. 34 is an operational view in front elevation showing application of the wrapper blank to a link of the product forming chain;

FIG. 35 is an `operational View at a further stage in the chain circuit illustrating the volumetric measuring of the product to be formed and wrapped;

FIG. 36 is an operational view in `a still further stage of the chain circuit illustrating the molding of the product and the concomitant partial application of the wrapper thereto;

FIG. 37 is an operational view at a slightly later stage than FIG. 36, illustrating the sharp ydefinition of the edges of the shaped or molded product;

FIG. 38 is an operational view in elevation of a still further stage of the chain circuit illustrating the operation of the trailing edge and trailing corner fold-down mechamsm;

FIG. 39 is an operational view in elevation of the parts shown in FIG. 38 at a slightly later stage in the chain circuit and illustrating the overruning of the trailing edge and corner fold-down means relative to the travel 4of the chain link;

FIG. 40 is an operational view in plan illustrating the operation of the trailing edge and trailing corners folddown ymeans in conjunction with the fold-holding mechanism; l

FIG. 41 is an operational View in plan at a slightly later'stage in the chain circuit illustrating the operation of the fold-holding means, together with the leading edge and leading corner fold-down mechanism;

FIG. 42 is an `operational view in elevation illustrating the operation of the leading edge retaining mechanism.

GENERAL ORGANIZATION Referring now in particular to FIGS. 1 and 3, the machine can be seen to be supported on a rectangular base comprised of elongated bars 11 joined together by a plurality of cross bars 12 to constitute an open supporting framework for the machine. Suitably supported by the base near one end thereof is an upright cylindrical turret assembly hereinafter referred to as the product forming turret the operating parts of which are enclosed in a side cover 16 and a lid 17. Suitably supported by the base l@ near the other end thereof is another turret assembly hereinafter referred to as the wrapper sealing turret the operative parts of which are enclosed in a side cover 21 and a lid 22. Each of said turrets includes rotating means which serve as sprocket members, hereinafter to be more fully described, cooperating with an endless conveyor chain which extends between and around the outer half periphery of each turret in a substantially elliptical path. The chain is formed of interconnected individual links 26 each formed to dene product forming mold as hereinafter more fully described, A product supply chute delivers the loose product to be packaged to the front side of the turrent 15 by gravity feed from a supply source, not shown. An excess product collector 28 and an associated screw conveyor 29 serve to return the excess product to the product supply for reuse to thereby avoid product waste.

Disposed over the front reach of the chain 25 is an assembly constituting a wrapper blank fabricating mechanism mounted on a frame panel 31. The wrapper fabricating mechanism, as hereinafter more fully described, operates to produce a 2-ply wrapper blank from and 33 or 33a and apply an individual wrapper blank to the upper surface of each chain link while passing therebelow in the direction of the product forming turret 15. Disposed over the rear reach of the conveyor chain is an assembly constituting a wrapper mechanism for folding down the edges of the wrapper blank over the product carried by each chain link as each link progresses towards the wrapper sealing turret 20. A package ejecting mechanism is disposed over the front reach of the conveyor chain 25 alongside the wrapper fabricating assembly 30 to sweep the finished packages off the conveyor chain as they are delivered from the wrapper sealing turret 2t).

All of the aforementioned assemblies are driven from a common power source comprised of a motor 45 suitably mounted on the machine base 10 and which is operatively coupled to a reduction gear box 46 the output shaft of which carries drive chain sprockets 47, 48. Chain means 49 engaging sprocket 47 drives the rotating members of the product forming .turret 15 which in turn drives the conveyor chain 25 along with the rotating members of the wrapper sealing turret 20. Chain means 50 engaging with the sprocket 48 serves to drive the wrapper blank fabricating mechanism 30, the package ejector 40 and the wrapping mechanism 35.

The parts of the wrapper blank fabricating mechanism are shown in greater detail in FIGS. 7-13. This mechanism operates to produce the wrapper blank shown in FIGS. 27 and 33 and comprised of a rectangular section of the sheet material 32 superimposed and joined to a rectangular section of the wrapper sheet material 33. A more complete description of the wrapper blank may be had by reference to copending application entitled Contour Patty Wrapper bearing Ser. No. 306,573 and led Sept. 4, 1963. The upper sheet 32 of the wrapper blank is folded over upon itself in a double reverse fold to constitute a pleat 56 running longitudinally of the blank and constituting a tear strip for enabling easy opening oI we resultant wrapper. Secured to one end of the pleat or tear strip 56 is a short length of tape 57 of a color distinct from that of sheets 32, 33 and serving as a pull tab tor facilitating grasping of the strip. Adjacent to the sides of the pull tab are slits 58'cut in both sheets 32, 33 of the wrapper blank to start and direct the line of tear when the tear strip is pulled to open the wrapper. Edge 61 and adjacent corners 62, 63 may be considered the leading edge and corners, respectively, of the wrapper lamination v32, and edge 64 with adjacent corners 65, 66 may be considered the trailing edge and corners respectively. Edges 67, 68 are the side edges thereof. Similarly, edge 71 and adjacent corners 72, 73 may be considered the leading edge and corners respectively of the wrapper lamination 

26. A PRODUCT PACKAGING PROCESS COMPRISING, FABRICATING INDIVIDUAL WRAPPER BLANKS FROM CONTINUOUS SHEET MATERIAL, TRANSPORTING EACH OF SAID BLANKS CONTINUOUSLY IN A FLAT HORIZONTALLY DISPOSED STATE ALONG A PRESCRIBED COURSE, DEPOSITING THE PRODUCT TO BE FORMED ONTO A BLANK WHILE IT PROGRESSES THROUGH ONE STAGE OF SAID COURSE, COMPACTING SAID PRODUCT INTO A PREDETERMINED FORM WHILE PARTIALLY APPLYING SAID BLANK AROUND SAID FORM AS IT PROGRESSES THROUGH ANOTHER STAGE OF SAID COURSE, FOLDING THE EDGES OF SAID BLANK INTO OVERLAPPING FOLDS TO COMPLETELY 